DeWalt DW896 User manual

Definitions: Safety Guidelines
The definitions below describe the level of severity for each signal word. Please read the
manual and pay attention to these symbols.
DANGER: Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury.
NOTICE: Indicates a practice not related to personal injury which, if not avoided, may
result in property damage.
WARNING: To reduce the risk of injury, read the instruction manual.
General Power Tool Safety Warnings
WARNING! Read all safety warnings and all instructions. Failure to follow the
warnings and instructions may result in electric shock, fire and/or serious injury.
SAVE ALL WARNINGS AND INSTRUCTIONS
FOR FUTURE REFERENCE
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or
battery-operated (cordless) power tool.
1) WORK AREA SAFETY
a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b) Do not operate power tools in explosive atmospheres, such as in the presence
of flammable liquids, gases or dust. Power tools create sparks which may ignite the
dust or fumes.
c) Keep children and bystanders away while operating a power tool. Distractions can
cause you to lose control.
2) ELECTRICAL SAFETY
a) Power tool plugs must match the outlet. Never modify the plug in any way. Do
not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs
and matching outlets will reduce risk of electric shock.
b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators,
ranges and refrigerators. There is an increased risk of electric shock if your body is
earthed or grounded.
c) Do not expose power tools to rain or wet conditions. Water entering a power tool
will increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging
the power tool. Keep cord away from heat, oil, sharp edges or moving parts.
Damaged or entangled cords increase the risk of electric shock.
e) When operating a power tool outdoors, use an extension cord suitable for
outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
f) If operating a power tool in a damp location is unavoidable, use a ground fault
circuit interrupter (GFCI) protected supply. Use of a GFCI reduces the risk of electric
shock.
3) PERSONAL SAFETY
a) Stay alert, watch what you are doing and use common sense when operating a
power tool. Do not use a power tool while you are tired or under the influence
of drugs, alcohol or medication. A moment of inattention while operating power tools
may result in serious personal injury.
INSTRUCTION MANUAL
DW896 16-Gauge Nibbler
b) Use personal protective equipment. Always wear eye protection. Protective
equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection
used for appropriate conditions will reduce personal injuries.
c) Prevent unintentional starting. Ensure the switch is in the off position before
connecting to power source and/or battery pack, picking up or carrying the tool.
Carrying power tools with your finger on the switch or energizing power tools that have
the switch on invites accidents.
d) Remove any adjusting key or wrench before turning the power tool on. A wrench
or a key left attached to a rotating part of the power tool may result in personal injury.
e) Do not overreach. Keep proper footing and balance at all times. This enables
better control of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing
and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught
in moving parts.
g) If devices are provided for the connection of dust extraction and collection
facilities, ensure these are connected and properly used. Use of dust collection can
reduce dust-related hazards.
4) POWER TOOL USE AND CARE
a) Do not force the power tool. Use the correct power tool for your application. The
correct power tool will do the job better and safer at the rate for which it was designed.
b) Do not use the power tool if the switch does not turn it on and off. Any power tool
that cannot be controlled with the switch is dangerous and must be repaired.
c) Disconnect the plug from the power source and/or the battery pack from the
power tool before making any adjustments, changing accessories, or storing
power tools. Such preventive safety measures reduce the risk of starting the power tool
accidentally.
d) Store idle power tools out of the reach of children and do not allow persons
unfamiliar with the power tool or these instructions to operate the power tool.
Power tools are dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired before use. Many accidents
are caused by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp
cutting edges are less likely to bind and are easier to control.
g) Use the power tool, accessories and tool bits, etc. in accordance with these
instructions, taking into account the working conditions and the work to be
performed. Use of the power tool for operations different from those intended could
result in a hazardous situation.
5) SERVICE
a) Have your power tool serviced by a qualified repair person using only identical
replacement parts. This will ensure that the safety of the power tool is maintained.
Additional Specific Safety Instructions for Nibblers
• Hold tool by insulated gripping surfaces when performing an operation where the
cutting tools may contact hidden wiring or its own cord. Contact with a “live” wire will
make exposed metal parts of the tool “live” and shock the operator.
• Cut material at or below rated capacity. Remember, material thickness increases as
gauge number deceases (14 gauge is thicker than 16 gauge). 14 gauge thickness is
.075" (1.9 mm); 16 gauge is .060" (1.5 mm).
• NEVER have any part of your body near the blades. Serious personal injury may result.
• Keep hands away from cutting area. A moment of inattention while operating power tools
may result in serious personal injury.
• ALWAYS wear gloves when handling sheet metal. The edges are sharp and can cause
serious personal injury.
• Firmly secure the piece of metal to be cut to prevent movement during cutting.
•ALWAYS start tool before engaging material to be cut.
• Always wear safety shoes to protect your feet from sharp metal debris on the floor.
• DO NOT use the nibbler with any kind of accessory or attachment.
• Keep all screws tight. Check periodically for loosening.
•Do not place anything into the motor housing openings.
• Clean out your tool often, especially after heavy use. Dust and grit containing metal
particles often accumulate on interior surfaces and could create an electric shock hazard.
• Stay clear of end pieces that may fall after being cut off. Contact with a sharp edge
could result in personal injury.
• Always keep the power cord away from the edge of the material being cut. Sharp
edges can result in the cord insulation being cut. This condition may create an electrical
hazard.
•Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or
long hair can be caught in moving parts.
•An extension cord must have adequate wire size (AWG or American Wire Gauge)
for safety. The smaller the gauge number of the wire, the greater the capacity of the cable,
that is 16 gauge has more capacity than 18 gauge. An undersized cord will cause a drop in
line voltage resulting in loss of power and overheating. When using more than one extension
to make up the total length, be sure each individual extension contains at least the minimum
wire size. The following table shows the correct size to use depending on cord length and
nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge
number, the heavier the cord.
Minimum Gauge for Cord Sets
Ampere Rating
Volts Total Length of Cord in Feet (meters)
120V 25 (7.6) 50 (15.2) 100 (30.5) 150 (45.7)
240V 50 (15.2) 100 (30.5) 200 (61.0) 300 (91.4)
More
Than
Not More
Than AWG
0 6 18 16 16 14
610 18161412
10 12 16 16 14 12
12 16 14 12 Not Recommended
WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses.
Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY
EQUIPMENT:
• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI S12.6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection.
WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities contains chemicals known to the State of California to cause cancer, birth
defects or other reproductive harm. Some examples of these chemicals are:
• lead from lead-based paints,
• crystalline silica from bricks and cement and other masonry products, and
• arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To
reduce your exposure to these chemicals: work in a well ventilated area, and work with approved
safety equipment, such as those dust masks that are specially designed to filter out microscopic
particles.
•Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling,
and other construction activities. Wear protective clothing and wash exposed areas
with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may
promote absorption of harmful chemicals.
WARNING: Use of this tool can generate and/or disperse dust, which may cause serious and
permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection
appropriate for the dust exposure. Direct particles away from face and body.

WARNING: Always wear proper personal hearing protection that conforms to ANSI
S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product
may contribute to hearing loss.
• The label on your tool may include the following symbols. The symbols and their definitions
are as follows:
V.....................volts A.........................amperes
Hz...................hertz W........................watts
min .................minutes or AC.............alternating current
or DC.....direct current or AC/DC......alternating or direct current
...................Class I Construction no.......................no load speed
.......................
(grounded) n.........................rated speed
...................Class II Construction .......................earthing terminal
(double insulated) ........................safety alert symbol
…/min ............per minute BPM ...................beats per minute
IPM.................impacts per minute RPM...................revolutions per minute
SPM ...............strokes per minute sfpm...................surface feet per minute
SAVE THESE INSTRUCTIONS FOR FUTURE USE
Motor
Be sure your power supply agrees with the nameplate marking. Voltage decrease of more than
10% will cause loss of power and overheating. DEWALT tools are factory tested; if this tool does
not operate, check power supply.
COMPONENTS (Fig. 1)
WARNING: Never modify the power tool or any part of it. Damage or personal injury could
result.
A. Punch C. Paddle Switch
B. Die D. Lock Button
INTENDED USE
The DW896 16-gauge nibbler has been designed for professional cutting at various work sites
(i.e., construction sites). DO NOT use under wet conditions or in presence of flammable liquids
or gases.
These 16-gauge nibblers are professional power tools. DO NOT let children come into contact
with the tool. Supervision is required when inexperienced operators use this tool.
ADJUSTMENTS
WARNING: To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when making
repairs. An accidental start-up can cause injury.
Setting the Cutter (Fig. 2, 3)
The cutter can be set to cut in any direction relative to the body. Release the set screw in the
knurled ring (F) with key provided and unscrew the ring by rotating in a counterclockwise direction
as viewed from the cutter.
Loosen ring just enough to be able to rotate the die (B). Set the die so that the connecting
web (E) is on the opposite side of the direction of cut. Fully tighten the knurled ring and lock by
tightening the set screw.
Punch and Die Replacement (Fig 4, 5)
After a period of cutting, the punch will become blunted and require replacement. At the same
time, check the die for sharpness and replace if necessary.
1. To remove the die, release the knurled ring (F). Having removed the die (B), rotate the
motor by turning the armature fan, accessible through the side cooling slot, until the punch
retaining nut is clear of the face of the gearbox.
2. With the spanner provided, release this nut (G) counterclockwise and remove the punch (A),
Figure 5. Assemble in reverse order.
OPERATION
WARNING: To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when making
repairs. An accidental start-up can cause injury.
Switches (Fig. 1)
To start tool, depress the paddle switch (C). To turn the tool off, release the paddle. The paddle
switch can be locked on by engaging the lock button (D) located near the rear of the tool, while
holding the paddle depressed. Always be sure that the tool is not locked on before plugging in.
To turn the tool off when it is locked on, squeeze and release the paddle once.
Cutting Tips (Fig. 2, 6–8)
• Make sure the knurled ring (F, Fig. 2) is tight prior to use. Keep fingers away from cutter and
other moving parts.
• The nibbler cuts a slot in the work 6 mm wide so remember to compensate for this when
marking out and calculating material requirements.
• When starting the cut from an edge, place the nibbler so the slot in the die engages the work
and the edge is against the punch, which is the moving part when cutting (Fig. 6).
• Start the nibbler by depressing the paddle switch. Hold the body parallel to the work
surface. Exert only enough forward pressure to start the nibbler cutting and maintain this
pressure. Extra pressure will not increase the rate of cut as the amount of material removed
at each cutting stroke is fixed and the rate of cut is dependent only on the speed of the
nibbler.
• The cutting line of the work should be lightly coated with oil to lubricate the punch and die
while cutting.
NOTE: Punch and die should be lubricated by immersing in a good quality cutting oil
approximately every 30 feet of cutting.
• When the cut is to be started or finished within the periphery of the work, a 1/2" (13 mm)
hole must first be drilled in the work at the start or finish point. This enables the die to be
entered or withdrawn as it is larger in diameter than the slot being cut in the work (Fig. 7).
• Circular holes should be cut in the manner shown in Figure 8, starting at the 1/2" (13 mm)
diameter hole within the circle.
MAINTENANCE
WARNING: To reduce the risk of injury, turn unit off and disconnect it from power
source before installing and removing accessories, before adjusting or when making
repairs. An accidental start-up can cause injury.
Cleaning
WARNING: Blow dirt and dust out of all air vents with clean, dry air at least once a week.
To minimize the risk of eye injury, always wear ANSI Z87.1 approved eye protection when
performing this.
WARNING: Never use solvents or other harsh chemicals for cleaning the non-metallic parts
of the tool. These chemicals may weaken the plastic materials used in these parts. Use a cloth
dampened only with water and mild soap. Never let any liquid get inside the tool; never immerse
any part of the tool into a liquid.
Lubrication
Your tool was properly lubricated before leaving the factory. In from two to six months,
depending upon use, take or send your tool to a DEWALT Service Center or other qualified
service organization for a complete cleaning, inspection and relubrication.
Tools used constantly on production or heavy duty jobs or exposed to heat may require more
frequent lubrication. Tools “out of service” for long periods should be relubricated before being
put back into service.
Motor Brushes
When the brushes on this tool become worn out, the tool will automatically stop and prevent
damage to the motor. Brush replacement should be performed by DEWALT service centers.
Accessories
WARNING: Since accessories, other than those offered by DEWALT, have not been tested
with this product, use of such accessories with this tool could be hazardous. To reduce the risk
of injury, only DEWALT recommended accessories should be used with this product.
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and adjustment
(including brush inspection and replacement) should be performed by a DEWALT factory
service center, a DEWALT authorized service center or other qualified service personnel.
Always use identical replacement parts.
B
C
A
FIG. 1
FIG. 2
FIG.6 FIG. 7
FIG. 8
F
DC
FIG. 3
B
E
DIRECTION OF CUT
FIG. 4 F
B
FIG. 5
A
G
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